Apparatus for coating fibrous glass with molten metal



May 20, 1958. G. SLAYTER ETAL 2,835,221

APPARATUS FOR COATING FIBROUS GLASS WITH MOLTEN METAL Filed May 28, 1953 2 Sheets-Sheet l INVENTORS Games 5 Layfe r. Gerard. de PLolenc.

G. SLAYTER ETAL 2,835,221

May 20, 1958 APPARATUS FOR COATING FIBROUS GLASS WITH MOLTEN METAL 2 Sheets-Sheet 2 Filed May 28, 1953 INVENTORS Games Slavier A'TTYS.

F I 4 Gerard de Piolenc BY Q W United States Patent- APPARATUS FOR COATING FIBROUS GLASS WITH .MOLTEN METAL Games Slayter, Newark, and Gerard de Piolenc, Granville, Ohio, assignors to Owens-Corning Fiberglas Corporation, a corporation of Delaware This invention relates to fibrous glass and particularly to fibers treated in such a manner as to provide strands, yarns and other textile materials having increased abrasion resistance,.knot strength and other improved properties.

It is an object of this invention to apply a metal coating to fibrous glass to protect the surfaces thereof and to enhance the properties of the resulting fibers.

It is a further object to provide apparatus for coating fibrous glass continuously while the fibers are being formed.

It is also an object to provide such apparatus which is adapted for coating a plurality of fibers which can then be gathered together in the form of a strand, yarn, or other textile product.

In the drawings:

Figure 1 is a front elevational view of apparatus for carrying out the invention;

Figure 2 is a side elevational view of the same apparatus;

Figure 3 is a sectional view of the roll applicator;

Figure 4 is another sectional view of the roll applicator; and

Figure 5 is a sectional view of another embodiment of the roll applicator.

Former attempts have been made to provide glass fibers with a coating of a metal which substantially surrounds the fiber and protects it from adjacent fibers in a strand. By coating with metal, it has been found that the abrasion resistance of the fibers is increased to such an extent that strands, yarns and fabrics of these fibers have greatly increased resistance to abrasion, flexing, knotting and any other working which is encountered in the use of these textile fibers. All former methods and apparatus have been diflicult to adapt to continuous methods which could be used at the fiber forming speeds of from 3,000 feet per minute up to 10,000 feet per minute or more used in producing fibrous glass products by the use of pulling wheels, pulling rolls, collet winders or the like.

In accordance with this invention the molten metal is applied with a roll applicator which is found to be particularly adapted, for applying metal to fibers while they are being formed at high speeds in a continuous and efiicient manner.

The apparatus comprises a feeder 11 having a plurality of tips 12, a roll applicator 13, a graphite gathering wheel 14, a traversing device 15 and a collet winder 16, see Figures 1 and 2. The roll applicator 13 is mounted upon supporting members 17 and 18 in such a manner that it can be moved into and out of operating position as shown in Figure 2.

Referring to Figure 3, the roll applicator comprises a metal tank 19 provided with slotted lugs 21 and 22 which are adapted for slidably engaging supporting members 17 and 18. The metal tank 19 is provided with a heating coil 23 which is embedded in a layer of a suitable refractory 24 and a graphite lining 25. The metal tank also has a hinged cover 26, see Figure 4. Hinged cover 26 is provided with an inlet opening 27. Mounted within the metal tank is a graphite roll 28 within which is disposed a stationary core 29 which is provided with a heating coil 42. Stationary core 29 is mounted upon a supporting arm 31 which is secured to the metal tank 19. Core 29 has a hollow shaft 32 through which leads 33, 33 pass. These leads 33, 33 -are connected to heating coil 42 disposed within stationary core 29, see Figures 3 and 4. Graphite roll 28 is journalled on bearings 34, 35 which are mounted upon the ends of metal tank 19. The graphite roll 28 is provided with a shaft 36 which has secured thereto a sheave 37 provided with driving belt 38. Heating coil 23 is provided with leads 39, 39. The metal tank and graphite liner have a hole 41 therethrough which provides an access opening for the addition of metal to the mass of molten metal 43.

In using this apparatus it has been discovered that a very suitable coating metal is zinc which melts at about 787". F. and may be applied at a temperature of about 840 F. The metal to be applied is melted within tank 19. The operator pulls the primary fibers 44 downwardly and gathers them together and positions them within the groove of the graphite gathering wheel 14 which is turned slowly by an electric motor not shown in the drawings. The resultant strand 45 formed by gathering the primary fibers is pulled downwardly and wrapped about collet 16 and at the same time collet 16 is rotated as indicated by the arrow in Figure 1.. The strand is wound upon the collet. When collet 16 is rotated the traversing device 15 likewise rotates and causes the strand to traverse back and forth on a tube 46 which has been placed upon the collet 16. A package of the strand is I formed upon the tube 46 substantially as shown in Figure 2. The strand travels at speeds of from 3,000 to 10,000 feet per minute as desired.

After the strand is being uniformly formed, roll applicator 13 is moved forward on supporting members 17 and 18 until it reaches the position shown in full lines in Figure 2. When the roll applicator is in this position the of the metal from this layer is picked up by a wiping action of the primary fibers 44, 44 in such a manner as to coat them.

In this manner a strand comprising a plurality of metal coated fibers is wrapped into a package upon a tube on the collet winder 16.

Instead of using the roll applicator shown in Figures 3 and 4, a device such as that shown in Figure 5 may be used. This roll applicator comprises two rolls one of which is partially submerged in the molten metal and another of which contacts the first mentioned roll and transfers the molten metal from the partially submerged roll to the primary fibers themselves. The partially submerged roll 47 rotates in the direction indicated by arrow in Figure 5 and delivers metal upwardly to the upper roll 48 which contacts roll 47. The molten metal transfers to and forms a layer of metal upon upper roll 48 from which it transfers to the primary fibers emitting from a bushing or feeder substantially as shown in Figures 1 and 2.

Metal is supplied to the roll applicator by introducing molten metal through opening 41 or by gradually inserting a wire or a rod of the appropriate metal through opening 41 into the molten metal where the rod or the like will melt. If necessary, in order to replenish the supply of metal, a sheet of the appropriate metal can be gradually inserted through a wide slot in the tank which may replace the "single hole shown in-the drawings.

While the operation is in progress it may be desirable to add an inert gas such as nitrogen through the inlet opening 27 in the hinged cover 26. This gas will substantially fill the chamber above the molten rnetaltendingto prevent oxidation at the surface of the metal. The gas will flow outwardly from the chamber 49 through the openings between the hinged cover 26 and the graphite roll 28 and the metal tank 19 and the graphite roll 28.

Although zinc has been disclosed as the metal which may be applied using the apparatus shown in the drawings, itshould be understood that other metals and alloys of metals may likewise be used. For instance, zinc alloys including zinc-lead and zinc-aluminum alloys can be used. 97:3 zinc-aluminum alloy or 98:2 zinc-aluminum alloy are very satisfactory. Other suitable alloys include lead alloys containing from 0.5 to 5% zinc. It has been found that drossing is very low in lead alloys'having at least 1% zinc or tin. Likewise lead alloys having 0.01% antimony or 0.02% aluminum have been found very satisfactory.

Any metal which melts at reasonable low temperatures can be transferred to the fibrous glass with the equipment of this invention. Alloys which melt at ternperatures above room temperature and up to about l,000 F. may be used. Metals which have melting points of from about 100 to l,000 F. are preferred with special preference being given to metals which melt at or above about 400 F.

The applicator of this invention may be used with any attenuating device including pulling rolls, pulling wheels, collet winders, crimping gears and the like.

Other materials besides metals and metal alloys may be applied to fibrous glass with the equipment of this invention. For instance, a hot melt comprising gelatine and copper acetate is readily applied to fibers as they are being formed by the roll applicator. 'I'he hotmelt is prepared by heating gelatine and water in a suitable container and then adding powdered copper acetate to the gelatine and water mixture. This hot melt is then introduced into the metal tank and the fibers treated. These treated fibers are then heated in an oven through which they pass continuously and a metallic copper coat is formed thereon.

Although nitrogen gas has been disclosed as a means for tending to prevent oxidation at the surface of the molten metal it should be understood that other inert gases may be used and furthermore the surface of the molten metal may be coated with such a protective substance as vermiculite or the like with or without the use of an inert gas also.

A graphite roll is preferred as the transferring means for the molten metal; however, the roll may be a steel roll which is chromium plated or one otherwise treated with a corrosion resistant material. For instance, a metal roll can be treated with a colloidal dispersion of graphite which is then baked on to provide a semi-permanent coat. The shape of the roll may be changed to that of a spheroid, an ellipsoid or the like in order to increase or decrease the wiping action of the fibers upon the roll.

The graphite roll has been shown with a core having a heating coil. This heating coil is preferably used to bring the roll up to operating temperature. The power to the core heating coil may be cut off after the graphite roll is once brought up to operating temperature. The only heat input which may be necessary after equilibrium conditions have been reached is directed to the melting coil which is in the refractory layer between the-graphite liner and the metal tank. .t may also be desirable to insulate the outer walls of the metal tank and the hinged cover in order to further conserve heat.

It should be understood that the roll or rolls of the applicator may be rotated either clockwise or counter clockwise at speeds of from about to 100 R. P. M. The roll shown in Figure 3 may be rotated so that its periphery is'travelling in a direction oppositethat of the strand. It has been foundthat such conditions provide adequate coating of the fibers with the metals being used. The roll applicator is placed in such a position relative to the feeder that the primary fibers are at an elevated temperature at the time they are coated with molten metal. The roll rapplicator is preferably positioned-adjacent the tips of the feeder with a clearance of from 2 to 3" being quite satisfactory. It is possible to coat the fibers when they are not at an elevated temperature, however, it is preferred to have the primary fibers hot when they are being coated with metal.

The metal coated fibers may hie-treated with any suitable size composition by metering droplets of the composition from nozzle 10a upon gathering wheel 14 or by spraying the size from nozzle 10b upon the fibers at the gathering wheel or at the pad or other gathering device. For instance, white oil, waxes, gelatine and starch compositions, plasticized polyvinyl acetate compositions, rubbery compositions and-the like maybe applied to enhance the already greatly improved properties of the metal coated fibers; A suitable size composition may also be applied after the metal coating step by using a roll applicator 10 similar to roll 28 shown in Figure l whichtransfersa size to thefibers before they are gathered into a strand. The roll maybe grooved to maintain the fibers in a space-aparted relationship until they are coated with the size. All the applicators 10,1011 and 10b may be used together or anyone or any combination of these applicators may be used.

Metal coated fibers, strands, yarns and like textile products produced by the apparatus and-methods of the invention may be used in many pro'ducts, including the following: decorative fabrics, tapes, fishinglines, awnings, upholstery materials, ropes, reinforced resins, movie screens, clothing, clutch facings, reinforcing cords for rubber products including tires, garden hose, fire hose, conveyor belts,blankets, fanbelts, motor belts, erasers, rug padding, gloves and many more.

Although the invention has been described with respect to specific embodiments it should be understood that obvious modifications and variations may be made within the spirit and scope of the appended claims.

We claim:

1. Apparatus for coating advancing fibersof glass with metal comprising an applicator consisting essentiallyof a receptacle for abath of liquid metal and'a hollow graphite roll associated therewith, said receptacle comprising a metal tank and a graphite liner with a heating coil therebetween, said receptacle also being provided with a hinged cover adapted for enclosing-said bath of liquid metal, said hollow graphite roll journalled in said metal tank and disposed so as to contact said molten metal, means for rotating said hollow graphite roll to transfer said molten metal away from said bath andonto said advancingffibers, said hinged cover having an inlet for an inert gas which along with said bath of molten metal substantially fills said receptacle, and stationary core means for heating said hollow graphite roll.

2. Apparatus for coating advancing fibers ofglasswith metal comprising an applicator comprising a receptacle for a bath of liquid metal and a hollow corrosion-resistant roll associated therewith, said receptacle comprising a tank having a graphite liner and a heating coil, said hollow corrosion resistant roll journalled in .saidtank and disposed so as to contact said bath of liquid metal, and'having a stationary core disposed-Within the'hollow roll, means for heating said stationary core, m eans for rotating said roll, and inlet means for'introducing an inert gas above said bath of molten-metal.

3. Apparatus for coating advancing fibers withmetal comprising-a receptacle for maintaining a bath of'liquid metal, a hollow transfer member having a generally arcuate outer surface journalled in said receptacle and so disposed as to contact the liquid metal within said receptacle, means for rotating said transfer member with respect to said receptacle to coat said arcuate surface with a liquid metal, and stationary core means within said hollow transfer member, said stationary core means having a heating coil disposed therein for heating said hollow transfer member.

4. Apparatus for coating glass fibers comprising a tank having a graphite liner and a heating coil between said tank and liner, a hollow corrosion resistant roll disposed within said tank and adapted to rotate with its periphery in contact with molten metal in said tank, means for rotating said hollow roll to transfer molten metal from said tank to said fibers, stationary core means for heating said hollow roll, and means for positioning said tank and said hollow roll with respect to said glass fibers to place the apparatus into and out of operative coating position.

References Cited in the file of this patent UNITED STATES PATENTS 1,481,228 Rondelli Jan. 15, 1924 6 Taylor Oct. 3, Smith W June 20, Fisher Dec. 10, Staelin Dec. 24, Simison Feb. 10, Kleist Apr. 3, Biefeld Jan. 15, Grupe 1. Mar. 19, Bennett et a1 Dec. 20, Brennan 1 Nov. 4, Godley Dec. 16, Lowell Dec. 30, Zinn Nov. 17, Radtke et a1 Nov. 2, Nachtman Jan. 11, Biefeld et al. Nov. 8, Whitehurst et al Dec. 4,

FOREIGN PATENTS France Aug. 28, France Aug. 28, 

